US7098569B2 - Rotor assembly for a permanent magnet power electric machine - Google Patents
Rotor assembly for a permanent magnet power electric machine Download PDFInfo
- Publication number
- US7098569B2 US7098569B2 US10/927,544 US92754404A US7098569B2 US 7098569 B2 US7098569 B2 US 7098569B2 US 92754404 A US92754404 A US 92754404A US 7098569 B2 US7098569 B2 US 7098569B2
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- Prior art keywords
- hub
- rotor
- outer diameter
- rotor hub
- rotor assembly
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/22—Rotating parts of the magnetic circuit
- H02K1/27—Rotor cores with permanent magnets
- H02K1/2706—Inner rotors
- H02K1/272—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis
- H02K1/274—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets
- H02K1/2753—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets the rotor consisting of magnets or groups of magnets arranged with alternating polarity
- H02K1/278—Surface mounted magnets; Inset magnets
Definitions
- the present disclosure relates generally to electric machines, for example, permanent magnet motors and generators.
- Electric machines such as electric motors and generators, are used in many applications, including those ranging from electric vehicles to domestic appliances. Improvements in machine performance, reliability, efficiency, and power density for all types of electric motors are desirable.
- An electric machine converts electrical or electromagnetic energy into mechanical energy or conversely converts mechanical energy into electrical or electromagnetic energy.
- the permanent magnets used in rotor assemblies are disposed within axially extending pockets.
- the pockets are typically formed near the outer perimeter of the rotor hub, which is built up from laminations made from electric grade steel. Electric grade steel is used on rotor assemblies because it has a greater permeability for conducting the magnetic lines of force.
- the process of building up a rotor with laminations is done to reduce eddy current losses in the rotor hub, especially during higher rotation speeds.
- the rotor extends from its outer perimeter to an inner diameter that interfaces with a shaft.
- the total mass of the rotor assembly is one of the parameters that affects the acceleration characteristics of the electric motor, the cost of the rotor assembly, and the amount of stress experienced by the various components of the rotor assembly, among other things.
- Shafts used in electric machine are typically made from structural steel, which is slightly more dense and certainly stronger than electric grade steel.
- an electric motor of the Toyota Prius which is a hybrid vehicle, utilizes a hollow shaft with an integrated carriage.
- the carriage includes a central web having one end connected to the main shaft and the other end connected to a carriage support that extends axially in either direction away from the central web.
- a laminated rotor hub with permanent magnets is retained within the carriage support.
- the inclusion of the central web extending radially from the shaft creates unique balancing issues with respect to vibration modes.
- the bearing positions on the shaft of the Toyota Prius shaft must be positioned to minimize the bending stress arising from the central web.
- the Toyota Prius shaft provides dome marginal weight reduction benefits, the configuration of the rotor assembly is not readily convertible to other types or sizes of motors.
- Conventional rotor assemblies include rectangular-shaped rotor pockets in which the rectangular-shaped permanent magnets are disposed.
- the stress concentrations in the magnet pockets and in the rotor laminations exacerbate the localized stresses as the operating speeds increase.
- the permanent magnets exert an outward radial force on the magnet pockets, which results in the centrifugal forces being reacted at the outer corners of the pockets.
- the assemblies and components described herein provide a variety of ways to reduce the weight of a rotor assembly for an electric machine. Reducing the weight of the rotor assembly permits the rotor to rotate at higher speeds while meeting specific mass targets for electric machines in the automotive industry.
- a rotor assembly includes a rotor hub comprising a first portion and a second portion, the first portion comprising an outer diameter and an inner diameter, the first portion comprising a plurality of uniformly, circumferentially spaced magnet pockets, the second portion comprising an inner diameter and an outer diameter, the outer diameter of the second portion abutting with the inner diameter of the first portion, the second portion comprising a plurality of passages, each adjacent passage separated by spokes, each spoke comprising a uniform thickness with respect to an adjacent spoke, the spokes connecting the outer diameter of the second portion with a shaft attachment region, the region integrally and proximately formed with the inner diameter of the second portion; a first set of permanent magnets, a respective one of the permanent magnets of the first set of permanent magnets received in a respective one of the magnet pockets; and a shaft comprising an outer diameter sized to closely receive the inner diameter of the second portion of the rotor hub.
- an electric machine in another embodiment, includes a rotor assembly comprising a rotor hub and a shaft, the rotor hub comprising a first portion and a second portion, the first portion comprising an outer diameter and an inner diameter, the first portion comprising a plurality of uniformly, circumferentially spaced magnet pockets, the second portion comprising an inner diameter and an outer diameter, the outer diameter of the second portion abutting with the inner diameter of the first portion, the second portion comprising a plurality of passages, each adjacent passage separated by spokes, each spoke comprising a uniform thickness with respect to an adjacent spoke, the spokes connecting the outer diameter of the second portion with a shaft attachment region, the region integrally and proximately formed with the inner diameter of the second portion; a first set of permanent magnets, a respective one of the permanent magnets of the first set of permanent magnets received in a respective one of the magnet pockets; and a stator comprising a plurality of windings, the windings positioned to electromagnetically cause rotation of the rot
- a rotor assembly in another embodiment, includes a rotor hub comprising an outer diameter and an inner diameter, a plurality of uniformly, circumferentially spaced magnet pockets located between the outer diameter and the inner diameter; a first set of permanent magnets, a respective one of the permanent magnets of the first set of permanent magnets received in a respective one of the magnet pockets; an intermediate hub comprising an outer diameter and an inner diameter, the intermediate hub further comprising a plurality of lightening holes axisymmetrically arranged between a region bordered by the outer diameter and the inner diameter of the intermediate hub, the outer diameter of the intermediate hub being sized to closely receive the inner diameter of the rotor hub; and a shaft comprising an outer diameter sized to closely receive the inner diameter of the intermediate hub.
- an electric machine in another embodiment, includes a rotor assembly comprising a rotor hub, a shaft, and an intermediate hub, the rotor hub comprising an outer diameter and an inner diameter, a plurality of uniformly, circumferentially spaced magnet pockets located between the outer diameter and the inner diameter; a first set of permanent magnets, a respective one of the permanent magnets of the first set of permanent magnets received in a respective one of the magnet pockets; an intermediate hub comprising an outer diameter and an inner diameter, the intermediate hub further comprising a plurality of lightening holes axisymmetrically arranged between a region bordered by the outer diameter and the inner diameter of the intermediate hub, the outer diameter of the intermediate hub being sized to closely receive the inner diameter of the rotor hub; and a stator comprising a plurality of windings, the windings positioned to electromagnetically cause rotation of the rotor assembly.
- a rotor hub in yet another embodiment, includes an outer diameter and an inner diameter; a plurality of magnet pockets, the pockets formed in a region proximate to and slightly radially inward from the outer diameter of the rotor hub; and at least a first permanent magnet comprising a pole arc to pole pitch ratio of about 0.9 arranged within each magnet pocket.
- FIG. 1 is a cross-sectional view of an electric machine according to one illustrated embodiment.
- FIG. 2 is a front, left isometric view of a rotor assembly for an electric motor according to one illustrated embodiment.
- FIG. 3 is a cross-sectional view of the rotor assembly of FIG. 2 .
- FIG. 4 is a cross-sectional view of the rotor assembly of FIG. 2 along line 4 — 4 of FIG. 3 showing the rotor hub configured with circumferentially spaced passages and spokes.
- FIG. 5A is a cross-sectional view of another rotor assembly having reduced thickness spokes according to another illustrated embodiment.
- FIG. 5B is a cross-sectional view of another rotor assembly having a reduced number of passages and spokes according to another illustrated embodiment
- FIG. 6 is a front, left isometric view of a rotor assembly having an intermediate hub according to another illustrated embodiment.
- FIG. 7 is a cross-sectional view of the rotor assembly of FIG. 6 .
- FIG. 8A is a cross-sectional view of the rotor assembly of FIG. 6 along line 8 — 8 of FIG. 7 showing the rotor hub configured with an intermediate hub that includes lightening holes therein.
- FIG. 8B is a cross-sectional view of another rotor assembly having a different configuration of lightening holes in the intermediate hub.
- FIG. 9 is a cross-sectional view of a rotor assembly having a shaft torsionally coupled with a full-thickness rotor hub according to one illustrated embodiment.
- FIG. 10 is a cross-sectional view of a rotor assembly having an enlarged diameter hollow shaft according to one illustrated embodiment.
- FIG. 11 is a cross-sectional view of another rotor assembly having an enlarged diameter hollow shaft with a generally tapered region between an end plate and bearing according to one illustrated embodiment.
- FIG. 1 illustrates an electric machine 2 according to one embodiment of the present assemblies, devices and systems.
- the electric machine 2 of the illustrated embodiment comprises a housing 4 , a stator 6 , and a rotor assembly 10 .
- the stator 6 includes electrical windings, which are not shown, but are well known in the art.
- FIGS. 2 and 3 show the rotor assembly 10 comprising a rotor hub 12 , a shaft 14 , a number of permanent magnets 16 , and a banding layer 18 .
- the rotor assembly 10 further comprises a pair of end plates 20 .
- the shaft 14 is mounted on roller bearings 22 .
- the rotor assembly 10 is mass balanced to rotate about a centerline 24 . The mass balancing can be accomplished by removing or adding material to the end plates 20 .
- the rotor hub 12 includes a first portion 30 and a second portion 32 .
- the rotor hub 12 is built up from laminations, which is a process well known in the art to reduce the eddy current effect in the rotor hub 12 .
- the laminations are thin steel layers or sheets, which are stacked and fastened together by cleats, rivets or welds.
- the first portion 30 of the rotor hub 12 often referred to as the “active” portion of the rotor hub 12 , conducts the lines of magnetic flux.
- the dimensions of a cross-sectional area of the first portion 30 affect the efficiency of the device.
- the reluctance e.g., resistance
- one way to reduce the weight of the rotor assembly 10 is to reduce the cross sectional area of the second portion 32 of the rotor hub 12 .
- the first portion 30 and the second portion 32 can be integrally formed to achieve a monolithic or one-piece rotor hub 12 .
- first portion 30 and the second portion 32 can also be separate components that are mechanically joined, for example by an interference fit-up process.
- FIG. 4 shows the rotor assembly 10 of FIG. 2 .
- a dashed line 34 represents the demarcation between the first portion 30 and the second portion 32 of the rotor hub 12 .
- the shaft 14 is torsionally coupled with the second portion 32 of rotor hub 12 by complementary formed keyways 26 .
- the torsional coupling strength between the shaft 14 and the rotor hub 12 can be increased by providing an interference fit between the shaft 14 and the rotor hub 12 .
- the interference fit can be in addition to the keyways 26 or it can be the sole means of torsionally coupling the shaft 14 to the rotor hub 12 . In the illustrated embodiment, only two keyways 26 are shown, however one skilled in the art will understand and appreciate that the rotor assembly 10 may employ a greater or a lesser number of keyways 26 .
- the second portion 32 can further be configured with a reduced-weight cross-sectional profile that is capable of withstanding the operating stresses of the electric machine, for example stresses due to thermal cycling, centrifugal forces, and other forces.
- the rotor hub 12 may be operable between speeds of about 13,500–18,000 rpm.
- the rotor hub 12 can operate at temperatures up to about 120 degrees Celsius. In an alternate embodiment, the rotor hub 12 can operate at temperatures up to about 180 degrees Celsius.
- the lamination sheets that are used to build up the rotor hub 12 are typically made from an electrical steel, which has a lower strength than a structural steel.
- electrical steel which is sometimes referred to as “lamination steel”
- lamination steel can have a tensile strength/density ratio that is about 50% less than the tensile strength/density ratio of structural steel.
- the lamination steel may have a density of 7.6 g/cm 3 and a tensile strength of 550 MPa.
- Structural steel like that used for the shaft 14 , can have a density of 7.9 g/cm 3 and a tensile strength of 850 MPa.
- both the first portion 30 and the second portion 32 be solid. As explained, earlier, the first portion 30 needs to be substantially solid to efficiently conduct sufficient lines of magnetic flux. However, a solid second portion 32 adds a significant amount of material and attributes excess weight to the rotor hub 12 .
- the illustrated embodiment depicts the second portion 32 of the rotor hub 12 configured with a number of circumferentially spaced passages 36 separated by spokes 38 .
- the passages 36 and spokes 38 are adjacently located and connected to a shaft attachment region 40 .
- the shaft attachment region 40 provides sufficient material to form the keyways 26 and withstand the torsional stresses resulting from the interaction between the shaft 14 and the rotor hub 12 .
- the passages 36 extend axially through the second portion 32 of the rotor hub 12 as shown in FIG. 3 . Although eight passages 36 are shown in the illustrated embodiment, one skilled in the art will understand and appreciate that second portion 32 can be configured with a greater or lesser number of passages 36 .
- the illustrated embodiment includes eight magnet pockets 42 , each pocket configured to receive sixteen permanent magnets 16 .
- the permanent magnets 16 can be made from sintered neodymium iron boron, which is suitable for operation up to a temperature of at least 180 degrees Celsius.
- the first portion 30 of the rotor hub 12 can include a greater or a lesser number of permanent magnets 16 .
- the banding layer 18 which is formed around an outer diameter 28 of the first portion 30 of the rotor hub 12 .
- a plurality of ribs 44 separate the circumferentially spaced magnet pockets 42 .
- An epoxy is used to fill the space 46 remaining in the magnet pockets 46 that is not otherwise filled by the permanent magnets 16 .
- One epoxy that can be used to fill the remaining space 46 is a glass filled epoxy.
- the permanent magnets 16 can additionally or alternatively be bonded within the magnet pockets 42 with a magnetic adhesive such as a cyanoacrylate adhesive. In the illustrated embodiment, the permanent magnets 16 are provided with straight sides and a thickness of about 9.0 mm.
- the banding layer 18 provides radial reinforcement for the rotor hub 12 and the permanent magnets 16 .
- the banding layer 18 can protect the permanent magnets 16 against corrosion.
- the banding layer 18 is composed of a carbon/epoxy matrix. In one embodiment, the banding layer 18 is composed of a 65% carbon/epoxy matrix.
- the carbon/epoxy composite material is wet laid onto the rotor hub 12 where a bond is formed between an inner diameter of the banding layer 18 and the outer diameter 28 of the rotor hub 12 .
- a banding layer thickness in the range of about 1.00 mm to 2.00 mm is adequate for most electric machine applications.
- FIGS. 5A and 5B illustrate two alternative embodiments where each of the alternative embodiments differs from the previous embodiment only by the configuration of the passages 36 and spokes 38 .
- FIG. 5A illustrates one alternate embodiment of a rotor assembly 100 .
- the rotor assembly 100 has a rotor hub 112 , a shaft 114 , permanent magnets 116 , and a banding layer 118 .
- the passages 120 are widened, or stating this alternatively, the thickness of each spoke 122 is reduced. Such a reduction can be verified through the use of finite element analysis or prototype testing to insure that the spokes 122 retain enough cross-sectional area to support the first portion 124 of the rotor hub 112 . Now referring to FIG.
- the rotor assembly 200 is similar to the previous embodiment in that it has a rotor hub 212 , a shaft 214 , magnets 216 , and a banding layer 218 .
- the rotor hub 212 is configured with a fewer number of passages 220 and likewise a fewer number of spokes 222 .
- the relative weight reduction in a range of about 25%–35% may be achieved with any of the above embodiments.
- the stated weight reduction is in comparison to a solid rotor hub, specifically a solid second portion of a rotor hub.
- FIGS. 6 , 7 and 8 A illustrate a rotor assembly 300 according to another embodiment of the present assemblies, devices and systems.
- the rotor assembly 300 is similar to the previous embodiment in that it has a rotor hub 312 , a shaft 314 , magnets 316 , and a banding layer 318 .
- the rotor hub 312 differs from that of FIGS. 2 through 5B in that an intermediate hub 320 is substituted for the second portion 32 of the embodiment depicted in e.g. FIG. 3 .
- FIG. 8A shows the intermediate hub 320 located between the rotor hub 312 and the shaft 314 .
- the intermediate hub 320 is made from aluminum in the present embodiment.
- the tensile strength of aluminum in comparison to its low density makes aluminum a good component for the intermediate hub 320 .
- the intermediate hub 320 can be interference fit with the shaft 314 . Due to the range of operating temperatures of the rotor assembly 300 , the interface pressure developed during the interference fit generation between the intermediate hub 320 and the shaft 314 can be increased.
- One method of developing a high interference fit between the intermediate hub 320 and the shaft 314 is to heat up the intermediate hub 320 , assemble it with the shaft 314 , and then allow the assembly to cool.
- the intermediate hub 320 also physically interfaces with the rotor hub 312 .
- the torsional coupling of the intermediate hub 320 with the rotor hub 312 can be accomplished with keyways 322 .
- the torsional coupling of the intermediate hub 320 with the rotor hub 312 can be mechanically accomplished with an interference fit, bonding, welding, or some other process.
- the weight of the intermediate hub 320 can be further reduced by the addition of lightening holes 324 , which can extend all the way through the axial length of the intermediate hub 320 .
- FIG. 8B illustrates a rotor assembly 400 , which is similar to the rotor assembly 300 of FIG. 8A except that an intermediate hub 420 includes a number of larger lightening holes 424 .
- an intermediate hub 420 includes a number of larger lightening holes 424 .
- the size, shape, and orientation of the lightening holes 424 can vary depending on any number of factors.
- the lightening holes 424 can be configured to augment the mass balancing of the rotor assembly 400 . Consequently, the relative weight reduction of the embodiments shown in FIGS. 6 , 7 , 8 A, and 8 B, when compared to a solid rotor hub, specifically a solid second portion of a rotor hub, is in the range of about 15%–25%.
- FIG. 9 illustrates a cross-sectional view of a rotor assembly 500 according to one embodiment of the present assemblies, devices and systems. Only significant differences between the present embodiment and the above embodiments will be identified.
- a number of permanent magnets 502 are arranged around an outer portion 504 of a rotor hub 506 .
- Each of the permanent magnets 502 has an annular shape with an inner arc 508 and an outer arc 510 .
- the permanent magnets 502 can be recessed into the rotor hub 506 and retained with the rotor hub 506 by a banding layer 512 .
- a magnet adhesive (not shown), such as a cyanoacrylate adhesive, can be used to bond the permanent magnets 502 with the rotor hub 506 and/or the banding layer 512 .
- the permanent magnets 502 are configured to have an arc measurement 514 .
- the arc measurement 514 is in the range of about 35.5–45.5 degrees, the thickness and thus the weight of the permanent magnets 502 can be reduced.
- the arc measurement 514 is about 40.5 degrees, which correlates to a pole arc to pole pitch ratio of 0.9.
- the magnet thickness can be reduced to about 7.5 mm when the arc measurement 514 is about 40.5.
- Testing has indicated that magnetic loading and electromotive force (EMF) begin to fall off at pole arc to pole pitch ratios below 0.9. In order to counter this phenomenon, additional electrical loading would be required, but in turn, this results in greater copper losses (i.e., I 2 R losses).
- EMF electromotive force
- FIG. 10 illustrates a rotor assembly 600 with a large diameter, hollow shaft 602 rotationally coupled to a rotor hub 604 .
- One purpose of the hollow shaft 602 is to replace the second portion 32 of the rotor hub 12 shown in FIGS. 3 and 4 .
- the rotor hub 604 could be mounted directly to the hollow shaft 602 whether with complementary keyways, an interference fit, or some other mechanical coupling method.
- FIG. 11 illustrates another rotor assembly 700 with a large diameter hollow shaft 702 .
- a rotor hub 704 can receive the hollow shaft 702 .
- the hollow shaft 702 of the illustrated embodiment has a blended section 706 that blends into each journal end 708 .
- the blended section 706 can reduce localized stress concentrations and smooth out the load path.
- the embodiments with the hollow shafts 602 , 702 illustrated in FIGS. 10 and 11 would not only reduce the overall weight of the rotor assembly, but also reduce the part count of the rotor assemblies 600 , 700 .
- One advantage of the embodiments of the rotor assemblies discussed herein is that at least a majority of any intricately shaped portions of the rotor assembly are within the laminated region of the rotor assembly. In doing such, the other rotor assembly components can have designs that are easier to manufacture, thus reducing production complexity and cost.
Abstract
Description
Claims (17)
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
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US10/927,544 US7098569B2 (en) | 2004-07-30 | 2004-08-26 | Rotor assembly for a permanent magnet power electric machine |
CA002514096A CA2514096A1 (en) | 2004-07-30 | 2005-07-29 | Rotor hub and assembly for a permanent magnet power electric machine |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US60893004P | 2004-07-30 | 2004-07-30 | |
US10/927,544 US7098569B2 (en) | 2004-07-30 | 2004-08-26 | Rotor assembly for a permanent magnet power electric machine |
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US20060043811A1 US20060043811A1 (en) | 2006-03-02 |
US7098569B2 true US7098569B2 (en) | 2006-08-29 |
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US10/927,544 Active US7098569B2 (en) | 2004-07-30 | 2004-08-26 | Rotor assembly for a permanent magnet power electric machine |
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CA (1) | CA2514096A1 (en) |
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